BEYOND ELECTRICITY AND CONTROL TO ANOMALY DETECTION AND MACHINE LEARNING - FEATURES: INDUSTRY 4.0 + IIOT ENERGY MANAGEMENT + THE INDUSTRIAL ...
←
→
Page content transcription
If your browser does not render page correctly, please read the page content below
FEATURES: · Industry 4.0 + IIoT · Energy management + the industrial environment · Measurement + instrumentation · Transformers, substations + cables Beyond electricity and control to anomaly detection and machine learning
energy + information in industry
INDUSTRY 4.0 + IIOT COMMENT
Energy efficiency can make the difference
Iritron advises that integrated automation
and data acquisition systems are key to
T here seems to have been nothing quite
like the national energy utility to hammer
home just how important energy efficiency
Of course it was predicted, but no one
was really interested in hearing what was
being said at the time.
enabling real-time visibility and timeous
is. Energy efficiency, if tackled properly, will
decision making, improving operational
efficiencies and long-term business While the new build fell way behind save users money and will also essentially
sustainability. schedule and costs escalated, many of the ‘build’ additional power stations – in the
(Read more on page 3.) existing plants began to grind and squeak sense that, if we could reduce the load,
as the utility gallantly tried to maintain we’d be able to get away with our current kit
output. far more effectively.
Editor: Leigh Darroll
Then industries, and homeowners So with the news just in that we are back
Design & Layout: Darryl James
too, began to see opportunities. Some of at Stage 2 load shedding, let’s all look at our
Advertising Manager:
these were born of necessity (like onsite plants, our production lines, our offices and
Heidi Jandrell
Circulation: Karen Smith
generation capacity), while in other cases even our homes – and see if we actually can
Editorial Technical Director: Ian Jandrell owners saw a move to a far better and more make a real difference in how much energy
Publisher: Karen Grant sustainable future. we use.
Deputy Publisher: Wilhelm du Plessis Various industries considered gas, solar Many organisations have made massive
plants and even wind energy sources. The strides in this regard, but opportunities
thinking caps were on. remain for much of our industry. I can recall
Just like the corona virus, however, the the difficulty Electricity + Control had, as a
energy supply crisis is going nowhere fast. magazine, trying to convince people that
Audited circulation: Quarter 1 (January-March) 2021
Total print and e-editions: 9559 Load shedding and a severely restricted energy simply has to be – in all cases – a
capacity to deliver baseload will be with us carefully monitored parameter that speaks
for some years to come. to the efficiency of a plant.
Published monthly by: Perhaps fifteen years ago many still had
This is when it becomes almost a national
Crown Publications (Pty) Ltd
imperative to look again, and very seriously, the view that energy was simply a cost, and
Cnr Theunis and Sovereign Sts,
at energy efficiency. the efficiency of the process had little to
Bedford Gardens, PO Box 140,
I recall vividly the days when, in as do with the energy efficiency of the plant.
Bedfordview 2008
much as we used to publish articles aimed (Perhaps many still do.) There was no real
Printed by: Tandym Print
specifically at this topic, few truly saw the incentive to think otherwise. Perhaps we
Telephone: +27 (0) 11 622 4770
value. And that’s not surprising. Energy were too convinced that energy, in our
E-mail: e-mail: ec@crown.co.za; admin@crown.co.za
was cheap (too cheap, truth be told) and it context, would simply never be a problem.
Website: www.crown.co.za/electricity-control
was well-documented that we had built too We had lots of coal, we had lots of power
many power stations, back in the day. stations, and energy was cheap.
CROSS PLATFORM CONTENT INTEGRATION:
Then, in the early part of this century, Now there is a real call to ask what the
* Electricity+Control Magazine * Online Edition our economy began to grow, and grow… correct and most appropriate approach
* Bi-monthly Newsletter * Website* LinkedIn (although, to be fair, that process has should be.
been successfully reversed to reduce Now is the time to begin to think deeply
any unnecessary strain on our generation about the real sustainability of everything
capacity). We found ourselves up the creek we do. Let’s get ahead of the curve this time
as it were – seemingly unable to stave off around.
the predicament.
Publisher of the year 2018 (Trade Publications)
Electricity+Control is supported by Ian Jandrell
PrEng IntPE(SA), BSc(Eng) GDE PhD,
FSAAE FSAIEE SMIEEE
Electricity + Control JUNE 2021 1
The views expressed in this publication are not necessarily those of the publisher,
the editor, SAAEs, SAEE, CESA or the Copper Development Association Africa
INDUSTRY 4.0 + IIOT CONTENTS
Features
INDUSTRY 4.0 + IIoT
4 A cooperative network for smart manufacturing
Eplan
6 Products + services
ENERGY MANAGEMENT + THE INDUSTRIAL ENVIRONMENT
10 Meeting Africa’s rising electricity demand
Ember 4
12 Smart energy management can minimise downtime
Martin van Zyl, Schneider Electric
13 Products + services
16 Renewable energy projects in Africa
MEASUREMENT + INSTRUMENTATION
20 Collaboration sees industry first for fire pump test lab
Instrotech
21 Products + services
13
TRANSFORMERS, SUBSTATIONS + CABLES
24 Streamlining renewables into the grid
National Grid Electricity Transmission and Smart Wires
25 Products + services
Regulars
1 Comment
Energy efficiency can make the difference
3 Cover article
Beyond electricity and control to anomaly detection and
24
machine learning
30 Engineering the future
Being part of the climate change solution
31 Cybersecurity
Increasing threats against industrial control systems
32 Write @ the back
EPR Regulations: game-changing waste management rules
30
2 Electricity + Control JUNE 2021
COVER ARTICLE
Beyond electricity and control
to anomaly detection and
machine learning
F orty years ago companies started switching over from
pneumatic and relay logic to electronic automation and
control systems. At first these systems were all customised
automation but no integrated
data acquisition system. What many companies fail to
recognise is that without this real-time data visibility, their
or built-to-purpose with little or no scalability and re-use. timeous decision-making ability is lagging and so is their
Over time they have become commercial off-the-shelf market competitiveness. Making a decision to change
systems that are seen and used as commodities in the field hours after the event as opposed to seconds after the event
of plant automation. wastes time and resources and makes companies less
Even though a lot of industries still operate manual competitive. In the long run, this lag in decision-making can
systems and processes using a combination of manual lead to ruin. Therefore, having actionable information in real
labour and stand-alone equipment, there is a move to time is critical to improving the efficiency and effectiveness
greater automation and systems integration. Manufacturers of operations and ensuring long-term sustainability of
are looking to the automation industry to deliver additional manufacturing.
benefit in the form of business-process automation (as Real-time information, once available can also be
opposed to physical process and machine automation). This used for ML. By applying the appropriate algorithms to
higher level automation is commonly called Manufacturing a historical dataset, companies can identify anomalies
Operations Management (MOM) or a Manufacturing in equipment and process performance in real time.
Execution System (MES), and most automation companies This enables them to predict upcoming quality issues,
have added components of this to their product offerings. impending equipment failures, imminent process
These systems are typically more complex than normal deviations and others, so they can be prevented. The
automation systems, as the data exchanged is normally difference between the automation systems of forty years
contextualised information shared between different areas ago and ML systems today, is that the time for them to
or departments of the business. This requires operators to evolve to become commodities has already passed and
change the way they operate the manufacturing facility. the time for them to be widely adopted has decreased
Due to the complexity and risk, these systems have taken considerably. There are companies today (small, medium
longer to become widely accepted and it is only in the past and large) that have already invested in and are using
few years that they have become more common. ML solutions in their plants. Thinking that you have time
Over the same time, much has been said about the before these systems prove themselves and that they
Fourth Industrial Revolution (4IR), the Internet of Things present no threat to your business is a fallacy. Iritron can
(IoT), Artificial Intelligence (AI) and Machine Learning advise companies on MES, MOM and ML systems. □
(ML). These concepts, even though expressed in simple
terms, sound utopian or futuristic to most manufacturing
companies. Most believe they are not ready for any of this
as they operate manual systems or have only islands of
For more information contact Iritron.
Tel: +27 (0)12 349 2919
Actionable information in real time is critical to improving Email: gerhard.greeff@iritron.co.za
operational efficiency and long-term sustainability of Visit: www.iritron.co.za
manufacturing.
Electricity + Control JUNE 2021 3
INDUSTRY 4.0 + IIOT
A cooperative network for smart
manufacturing
The new partner network founded by EPlan towards the end of 2020 pools
the worldwide expertise of its cooperation partners to increase benefits
for customers. The EPlan Partner Network defines common binding goals
to boost integration along the value chain. Users benefit from the greater EPlan CEO, Sebastian Seitz.
continuity and integration, and the interchange among manufacturers
makes it easier for customers to integrate different systems.
E
ngineering solutions provider EPlan started its Partner the benefits for end users.”
Network (EPN) at the turn of the year. It provides a The goals are ambitious.
framework for existing and new partnerships to work “The connectors between
together in developing and marketing interfaces and is our systems should be
based on common binding goals to support this aim. The planned, developed, tested,
commitment increases customer benefits and enhances supported and marketed
quality. with at least the same rigour EPlan Senior Vice President
and soundness that we are Strategy & Corporate
Program, Marco Litto.
Interaction and integration accustomed to with our own
EPlan CEO Sebastian Seitz explains: “As well as using solutions. Together with our EPN partners, this will allow us
EPlan software, our customers use a variety of other to achieve a completely new level of customer focus,” Litto
software applications from various manufacturers in says. “Open interfaces and modern integrations will create
the ERP (Enterprise Resource Planning), PLM (Product opportunities that will benefit users of the various software
Lifecycle Management), PLC (Programmable Logic solutions and the partner companies themselves.”
Control), simulation and other environments. The effective
interaction of these various applications is especially Key players on board
important to them. As part of the EPN, we will therefore be Key players in automation globally – including Bosch
focusing on joint development of integrations as well as Rexroth, B&R, Endress+Hauser, Festo, ifm electronic,
quality assurance and support.” Mitsubishi Electric, Phoenix Contact, Pilz, Rittal and
Commenting on the motivation to found the EPlan Rockwell Automation – are already participating in the
Partner Network, the company’s Senior Vice President initiative. Software partners – such as configit, Contact
Strategy & Corporate Program, Marco Litto says: “The Software, encoway, Gain, ISD, ISG, keytech, machineering,
professionalisation of our network systematically increases Procad, Quanos and SAE – are also participating in the
new network. Other companies are being approached to
participate too and EPlan is in talks with many. For instance,
UDMTEK in Korea was the first Asian company to become
an EPN member and others will follow.
Rockwell Automation USA Vice President Global
Business Development, Tom O’Reilly says: “A digital thread
of data within and across organisations is one of the key
requirements to bringing the Connected Enterprise to
life. Together with EPlan, we support companies through
their digital transformation by enabling data consistency,
improving efficiency of engineering processes and
shortening time-to-market.”
Bosch Rexroth got involved at the start of the network.
The company’s Vice President of Sales, Steffen Winkler says,
The EPlan Partner Network brings together the expertise of “Configuration of automation solutions and the dynamic
cooperation partners with defined development goals. provision of exact device data are essential with regard to
4 Electricity + Control JUNE 2021
INDUSTRY 4.0 + IIOT
Industry 4.0. The Bosch Rexroth ctrlX Configurator enables
At a glance
easy configuration of complete ctrlX Automation solutions.
Collaboration is changing the way engineering solutions are developed for
By directly integrating our configurator into the EPlan
smart manufacturing.
Platform, users will receive all device data of the configured
Easy interaction of various software applications from different
system topology, including detailed product lists and CAD
manufacturers has become key to designing effective automation systems.
data, at the touch of a button. This integration ensures full
Open interfaces and modern integrations create opportunities that benefit
data consistency and reuse of product data throughout the
users of the software solutions and the partner companies themselves.
digital design phase.”
UDMTEK CEO Gi Nam Wang also has good reasons for
joining. “We decided to partner with EPlan through EPN solutions are playing an increasingly critical role, it’s becoming more
to leverage our industry-leading offerings and combine important for providers to coordinate integration across companies.
them with EPlan’s best-in-class engineering platform. We Seitz says, “With the EPN, we’re maximising the overall benefits of our
are excited to partner with a world-class company as we own solutions and those of our partners in the ecosystem of industrial
embark on our next phase of growth and innovation.” automation for shared customers. Together we’re creating a win-win
EPlan makes it easy for users and companies to benefit situation for customers and partners.” □
from the EPN. A partner area on the website provides par-
ticulars for companies involved in the network, information
about integrations, contact people and current news.
For more information visit: www.eplan-software.com
In this era of the digital transformation, when cloud
Cross-project collaboration Clear access rights and role assignments ensure data
The continuing digital transformation of engineering has security and provide flexibility for project access. Users of
seen EPlan also introduce a new service for cross-project EPlan Electric P8 and EPlan Pro Panel are already benefitting
collaboration – EPlan eManage – as part of its cloud services. from the integrated processes which enable them to upload
This lets users upload EPlan Platform projects into the cloud their projects into the cloud and transfer them back to the
environment and share and work on them there. EPlan Platform for further processing.
As a first step, a free version of the new cloud-based With just one click users can publish their project data
software solution was launched in March. A fee-based directly in EPlan eView. This allows defined stakeholders the
version of the software will be released in August and will offer opportunity to look at and comment on projects. It further
expanded functionality. enables cross-company review processes to be implemented
EPlan eManage makes it easy to upload, manage and digitally and, with its clear, central availability in the cloud,
share projects in the secure ePulse cloud environment. As to- eManage supports project participants in searching for
day’s ecosystem of industrial automation is characterised by specific content quickly.
many media discontinuities in the processing and transferring
of documentation, the advantages of this system are clear: Synchronised, current data
the EPlan Platform systems in connection with the new cloud EPlan eManage means that the EPlan Project is synchronised
service will network control cabinet manufacturers and pan- for all project participants and stakeholders. Changes in
el builders, OEMs and system integrators, and machine and the project are visible to all participants and the project
plant system operators. This means they can work together documentation is always current – across the entire project life
on a central project that can be synchronised on the EPlan cycle and even into operations and service scenarios.
Platform via eManage.
Eplan eManage allows Eplan Projects to be shared in the cloud with all Users of Eplan Electric P8 and Pro Panel can upload their projects into
project participants – enabling more collaboration in engineering. the cloud and transfer them back to the EPlan Platform.
Electricity + Control JUNE 2021 5
INDUSTRY 4.0 + IIOT : PRODUCTS + SERVICES
Leading new product introductions in electronics
As an authorised distributor reference, and a multiplexer for surveying the
Mouser Electronics Inc. is focused channel output voltages and currents.
on the rapid introduction of new - TDK InvenSense SmartIndustrial™ sensor plat-
products and technologies, giving forms are compact, high-precision, low-cost, ac-
customers an edge and helping celerometers and motion-sensing MEMS modules
speed time to market. Over 1 100 that give engineers a range of sensing choices for
semiconductor and electronic industrial applications.
component manufacturer brands - Intel RealSense™ ID F450/F455 is an
count on Mouser to help them out‑of‑the‑box, credit-card-sized solution that
introduce their products into the combines an active depth sensor with a special-
Mouser launched more than 483 new
global marketplace. Mouser’s ised neural network to deliver secure and accu-
products through just one month, April 2021.
customers can expect 100% rate facial authentication.
certified, genuine products that are fully traceable from - TE Connectivity’s MATE-AX miniaturised automo-
each manufacturer. tive coaxial connectors feature higher packaging
Through April 2021, Mouser launched more than 483 density to enable a 75% space reduction and 34%
new products ready for same-day shipment. weight savings compared to standard FAKRA
These are just a few of them. connectors.
- Analog Devices LTC2672 16-Bit digital to analogue
converter offers five-channel, current-source out- For more information visit: https://eu.mouser.com
put DAC, with selectable output ranges, precision or www.mouser.co.za
Sensor monitoring in OEM control cabinets
Turck is expanding its series of cabinet guards to analyse the data from the factory level directly from
with the addition of the IM18-CCM. The integrated their office desks. The Linux platform of the IM18-CCM
sensors of the narrow 18 mm device monitor also allows installation of any customised condition
temperature, air humidity and door distance, monitoring software. In this way, measured values can
in order to send this information via Ethernet to be pre-processed and prepared on the device for the
higher-level IT systems. External devices such specific requirements of the application.
as vibration sensors for monitoring machine or The IM18-CCM is the third model in Turck’s cabinet
equipment states can also be integrated via guard series. The two 12 mm devices IM12-CCM and
Modbus RTU and CAN. IMX12‑CCM come with on-board condition monitoring
The IM18-CCM is particularly suitable for OEMs software to monitor limit states and long-term data series.
wanting to provide basic condition monitoring
The 18 mm values in their IT systems. It detects critical states of the For more information contact Brandon Topham at
cabinet guard control cabinet directly in the field. Creeping changes Turck Banner.
with integrated
sensors bridges or systemic problems can also be detected through Tel: +27 (0)11 453 2468
OT to IT data long-term evaluations. The IM18-CCM thus bridges the Email: brandon.topham@turckbanner.co.za
communications. gap between the OT and IT worlds and enables users Visit: www.turckbanner.co.za
Combining IO-Link and OPC UA cloud-based systems via OPC UA, the Ethernet-based
protocol specifically designed for machine-to-machine or
Pepperl+Fuchs combines the advantages of IO‑Link and machine-to-cloud communication. The systems analyse
OPC UA in a single device, offering its customers the data for specific applications, such as predictive
IO-Link data communication from the lowest field level to the maintenance solutions in which an optical sensor, for
master with cloud to facilitate Industry 4.0 solutions. example, can proactively flag lens contamination and
OPC UA Although sensor data is currently typically stored thus prompt cleaning in good time before malfunctions
interface.
in central control systems that may be difficult to occur. The flow of data helps customers to increase
access, this solution now makes the information productivity and secure long-term business success as
available to decision-makers and AI systems digitalisation becomes ever more important.
wherever it is needed, worldwide. When used as a
sensor interface, IO-Link provides in-depth data to For more information contact Pepperl+Fuchs.
identify, configure parameters for, and diagnose a Email: info@za.pepperl-fuchs.com
sensor. The data can be forwarded to computer- or Visit: www.pepperl-fuchs.co.za
6 Electricity + Control JUNE 2021
INDUSTRY 4.0 + IIOT : PRODUCTS + SERVICES
Secure data exchange for Industry 4.0 applications
Data exchange is an important issue to look at when client applications plus definable access types. Apart
integrating the production (operational technology, OT) from full implementation of OPC UA security functions,
and management (information technology, IT) levels whitelists and blacklists can also be defined to control
in an organisation. This is due to the large number of data access from specific IP addresses, and detection
variables and non-standardised interfaces, as well as the of Denial of Service (DoS) attacks targeting OPC UA
need to support access privileges and specific security authentication is also included.
requirements. Although OPC UA has established itself
as a standard technology for achieving these goals, Benefits for customers
the devil is in the detail when it comes to implementing Whether customers are retaining existing setups or
successful Industry 4.0 applications. planning a new plant installation, deciding to deploy
the dataFEED Secure Integration Server offers a
Interface abstraction, data aggregation and security significant set of advantages when running Industry
The dataFEED Secure Integration Server product 4.0 applications. In one recent example, integrating
from Softing Industrial works as an abstract interface 1.5 million variables into an overall system was the
between the worlds of OT and IT, offering users a set challenge faced by a leading provider of power station
of key functionalities for efficient data exchange in a process control systems. However, accessing such a
single component. In its role as an aggregating server, large number of variables is a major stumbling block for
this middleware makes use of OPC UA’s address space many OPC UA clients. Because of this, the provider for
The dataFEED modelling, especially for interface abstraction and data the power station application chose to use the variable
secure integration aggregation. In the process, the interface abstraction filtering option to achieve targeted variable access
server enables handles changes or extensions within one domain (OT/ restrictions for individual OPC UA clients. In addition,
seamless, secure
IT) without any modifications then being needed in the only read access is granted to the individually configured
data exchange
for production other. Advantages here include the ease with which new variables. This prevents the unauthorised overwriting of
and management IT applications can be integrated into the overall solution, assigned data values.
levels. to exploit short innovation cycles in IT or make targeted In another example, a major supplier of automotive
changes to the production environment. parts similarly chose dataFEED Secure Integration Serv-
With data aggregation, data from multiple er specifically to handle variable aggregation and filtering
sources can be consolidated on a single OPC from multiple, heterogeneous OPC UA servers, giving the
UA server, so the IT application only needs OPC UA clients a standard, harmonised interface for ac-
to access one server. This simplification cessing all variables. In this case, the customer’s need to
to the communications infrastructure cuts implement a state-of-the-art security standard was anoth-
configuration effort for users. er key reason for choosing this solution.
Another key feature of the dataFEED
Secure Integration Server is its built-in For more information contact Systems Automation &
security model, with filters available to restrict Management.
the address space for individual OPC UA Tel: + 27 (0) 11 803 0570, email: claude@sam.co.za
New functions in secure remote service mGuard Secure Remote Service Connector app is
available in the PLCnext Store for this purpose.
10 years on from the original mGuard launch, Phoenix To keep customers’ data secure, the security-related
Contact is introducing version 2.11 of its mGuard Secure parameters of the mGuard Secure Remote Service have
Remote Service ecosystem to the market with added been brought in line with the recommendations of the
features and new system functions. German Federal Office for Information Security (BSI)
The system supports concerning encryption algorithms and lengths.
Android-based mobile With version 2.11, various subnets of a machine or
end devices for service system can now be easily added in the user interface. In
technicians and iOS- version 2.12 onwards, they are made available selectively
based Apple devices. to users or user groups with fine granularity.
On the machine side, Both version 2.11 and 2.12 of the remote maintenance
PLCnext Control devices ecosystem are available worldwide.
from Phoenix Contact
can also be easily and For more information contact Phoenix Contact.
securely connected Tel: +27 (0)11 801 8200
The mGuard Secure Remote Service ecosystem to the mGuard Secure Email: info@phoenixcontact.co.za
supports service technicians in the field. Remote Service. The Visit: www.phoenixcontact.com/en-za/
8 Electricity + Control JUNE 2021INDUSTRY 4.0 + IIOT : PRODUCTS + SERVICES
The Open Integration Network
How can field instruments and components be
easily integrated into automation systems? The
answer to this question is becoming increasingly
important as digitalisation of industrial produc-
tion progresses. The Endress+Hauser Open
Integration partner program unites 13 manu-
facturers that want to ensure the streamlined
interaction of their complementary products.
Recently flow control specialist Rotork joined the
partner network. Armin Nagel, Head of Sales CPI
EMEA at Rotork. [Source: Rotork]
“Having Rotork join our partner programme The partner programme aims to provide added value for
provides us with additional expertise in customers by ensuring the seamless integration of intelligent
assets. [Source: Rotork]
actuators, instrumentation and the larger flow
control market,” says Jörg Reinkensmeier, Marketing towards common customer benefits in a pre-
Manager at Endress+Hauser. “We will exploit this sales stage and to extend our scope as a
potential together with all our Open Integration partners, trusted partner in the market. The reliability
giving our customers freedom of choice.” and quality that we have come to expect from
The Open Integration cooperation partners test and Endress+Hauser is also a key driver at Rotork.
document the integration of their offerings and how The company, and I personally, look forward to
digitalisation may be fully used within typical process working together to help our partners provide
automation applications. Users benefit in two ways: by premium flow control solutions,” said Armin
Jörg Reinkensmeier, Marketing
being able to combine the best-of-breed products for Nagel, Head of Sales CPI EMEA at Rotork.
Manager at Endress+Hauser.
specific plant operations as well as fast and smooth
commissioning. Automation technology suppliers value The Open Integration Network
the advantages of the Open Integration programme as To date 13 companies have joined Endress+Hauser’s
well, as they can ensure the fine tuning of the combined partner programme. Members are well known
offering well in advance of installation and commissioning suppliers of control technology, fieldbus infrastructure,
at customers’ sites. measurement technology or actuator technology,
such as Auma Riester, Bürkert, Festo, Flowserve,
Flow control specialist Hima Paul Hildebrandt, Honeywell Process Solutions,
Rotork is a market-leading global provider of mission- Pepperl+Fuchs, Phoenix Contact, Rockwell Automation,
critical flow control and instrumentation solutions for oil Schneider Electric, Softing Industrial Automation, Turck
and gas, water and wastewater, power, and chemical, and from the beginning of 2021, Rotork.
process and industrial (CPI) applications. It helps
customers around the world to increase operational For more information contact Endress+Hauser.
efficiency, reduce environmental impacts, improve Tel: +27 (0)11 262 8000
product quality and provide safer working environments. Email: info.za.sc@endress.com
“This programme is a great opportunity to collaborate Visit: www.endress.com
AATF Virtual Connect! 2021
Africa Automation Technology Fair 2021 will be staged
virtually as AATF Virtual Connect! 7 to 9 September
2021. This was decided following feedback gathered
from exhibitor and visitor surveys and consultation with
industry stakeholders. The next in-person event has
been rescheduled for 9 to 11 May 2023.
In response to the automation industry’s request to
connect and come together in 2021, Reed Exhibitions
Africa created AATF Virtual Connect! which will take
place in September 2021 and again in 2022.
This will offer African and international industry
AATF Virtual Connect! is scheduled for September 2021.
decision makers and exhibitors a platform where they
can gain industry insights and have focused meetings For more information visit:
during the three-day event. www.africaautomationtechnologyfair.com
Electricity + Control JUNE 2021 9ENERGY MANAGEMENT + THE INDUSTRIAL ENVIRONMENT
Meeting Africa’s rising
electricity demand
An analysis of electricity supply globally has revealed that wind and solar showed resilient growth in
2020, despite the pandemic, forcing a record fall in global coal power. It indicates that almost a tenth
of global electricity was generated by wind and solar in 2020. In Africa, Morocco and Kenya are the
clear leaders and already ahead of the world average. However, data from 2014 to 2019 shows that
only a third of the rise in Africa’s electricity demand was met with renewables, and two-thirds with
fossil gas.
T
he Global Electricity Review, published by independ- 9% of its electricity in 2015 to 12% in 2019. Kenya has seen
ent energy think tank Ember, analysed electricity data a rapid acceleration in wind power, increasing from less
from every country in the world to provide an accu- than 1% in 2015 to 14% in 2019. Solar power remains at
rate view of the global electricity transition in 2020. less than 1% of Kenya’s electricity.
Many of Africa’s leading economies have yet to harness
2020 global power trends the potential of wind and solar power, which are now among
The pandemic brought the world to a halt in 2020 and the cheapest forms of new electricity. In 2019, Nigeria and
paused the world’s rising demand for electricity. The slight Algeria generated less than 1% of their electricity from wind
drop in demand (-0.1%) was the first fall since 2009, al- and solar, while Egypt increased to 3% in 2019 after re-
though it was smaller than the impact of the financial crisis. cent growth in solar power. South Africa generated 6% of its
Wind and solar power showed resilient global growth in electricity from wind and solar in 2020, tripling since 2015,
2020, despite the pandemic, up by 15% (+314 TWh) versus but still below the world average of 9.4%.
2019. The growth in wind and solar helped push coal power Across the G20, many countries mirrored the global
to a record fall of 4% (-346 TWh). average wind and solar share (9.4%) in 2020, including
India (9%), China (9.5%), Japan (10%), Brazil (11%), the
Wind and solar US (12%) and Turkey (12%). Europe is leading the way, with
Globally wind and solar doubled in the past five years to Germany at 33% and the United Kingdom at 29%, giving
supply almost a tenth of global electricity in 2020. Among confidence in how wind and solar can be quickly built and
Africa’s leading economies, Morocco and Kenya had the integrated into the electricity system.
highest levels of wind and solar, respectively generating Emerging economies such as India and Turkey have
16% and 15% of their electricity from wind and solar in accelerated their deployment of wind and solar to reduce
2019. their dependence on fossil fuels. India’s wind and solar
Morocco has achieved a rapid increase in solar power, generation tripled in five years to provide 8.9% of total
increasing from near zero in 2015 to 4% of its electricity electricity production in 2020, now just below the global
generation in 2019. It also increased its wind power from average. Lower electricity demand and wind and solar
growth led to coal’s market share falling by 5% since
2015.
In Turkey, wind and solar provided 12% of electricity
generation in 2020, this share has tripled since 2015.
This helped to reduce gas and oil’s market share by
11% over the same period, however coal’s market share
continued to grow.
Fossil fuels still dominate
Fossil fuels generated 61% of the world’s electricity in
2020, down from 66% in 2015 when the Paris Agree-
ment was signed. Coal was the single largest source,
responsible for 34% of global electricity in 2020.
The dataset of global electricity generation revealed
that major African economies were significantly more
Gas and renewables are meeting Africa’s growing electricity demand. reliant on fossil fuels for electricity than the world
10 Electricity + Control JUNE 2021ENERGY MANAGEMENT + THE INDUSTRIAL ENVIRONMENT
average of 61%. Above-average levels of fossil fuels were
At a glance
observed in Nigeria (81%) and South Africa (89%) in 2020,
While Morocco, Kenya and SA have shown significant growth in solar and
and in Egypt (90%), Algeria (99%) and Morocco (79%) in
wind power, many of Africa’s leading economies have yet to harness the
2019. South Africa stands out with by far the largest share
potential of renewable energy sources.
of coal (86%) in Africa, over double the world average.
The dataset of global electricity generation reveals that major African
However, fossil fuels’ share of electricity generation
economies were significantly more reliant on fossil fuels for electricity than
is hugely varied across Africa, as many countries had far
the world average of 61%.
higher shares of clean electricity than the world average
The challenge remains to build renewables fast enough to keep up with
in 2020 (39%). Ethiopia, Kenya, Angola and Zambia all
rising electricity demand.
generated over 80% of their electricity from clean sources in
2019. Kenya recently pledged 100% renewable electricity
by 2030, confirming its commitment to a clean energy future.
Across the G20 there were also many countries with
fossil fuel shares above the global average in 2020. Five
G20 countries had over three-quarters of their electricity
supplied from fossil fuels in 2020: Saudi Arabia (100%),
South Africa (89%), Indonesia (83%), Mexico (75%)
and Australia (75%). In comparison, France and Brazil
generated only 9% and 14% of their electricity from fossil
fuels, respectively.
Africa’s rising electricity production
In Africa, electricity production is still increasing every year.
From 2014 to 2019, renewables met one third of Africa’s
Fossil fuels’ share of electricity generation varies widely across African countries.
growth in production, with gas making up the remaining two
thirds. Renewables growth in Africa has been accelerating variable energy sources grows, there will be new challenges for power
since 2015, but it has not yet been fast enough to meet all systems in Africa, especially for system operators who will have to
the rising demand. The rise in gas was particularly marked procure and manage complementary flexible resources to ensure
in North Africa, where there were the biggest increases in supply security and stability.”
electricity demand, and very little build-up of renewable Duncan Gibb, Renewables Project Manager and Analyst, REN21,
electricity. said: “It’s encouraging to see that Morocco and Kenya have made
As a continent, Africa – unlike Asia – has avoided a such progress with solar and wind power, and have reached high
coal-reliant electricity grid. There has been no growth in to- shares among African countries. Their success shows the impact of
tal coal generation since 2014, as South Africa’s falling coal effective political leadership and well-designed regulatory frameworks
generation was cancelled out by increases in Morocco and that create market conditions where renewables thrive. At the same
Zambia. In addition, there is very little coal capacity under time, more than half of the population in sub-Saharan Africa still lacks
construction or planned in Africa – only South Africa and access to electricity. Renewable energy, including solar and wind, can
Zimbabwe are building new coal. quickly and inexpensively help fill this gap. Ember’s Global Electricity
Commenting on the review, Peter Tunbridge, analyst at Review shows the huge potential for African nations to build affordable
Ember, said: “The challenge remains to build renewables renewables and provide electricity for their citizens.” □
fast enough to keep up with rising electricity demand, not
just for Africa but across the world. Emerging economies
For more information visit: www.ember-climate.org
such as India and Turkey are accelerating their deployment
of wind and solar beyond the increase in electricity demand,
to reduce their dependence on fossil fuels. Wind and solar The Global Electricity Review
have the potential to power Africa’s electric future, and This annual review analyses electricity data from every country
rapid deployment of these technologies will be essential for in the world to provide an accurate view of the global electricity
African countries to meet the rising demand for electricity transition in 2020. It aggregates generation data by fuel by coun-
and avoid a fossil gas trap.” try from 2000. 68 countries accounting for 90% of world electricity
Professor Anton Eberhard, Power Futures Lab at the generation have full-year data to 2020 and have formed the basis
University of Cape Town, said: “Solar and wind energy of an estimate for changes in worldwide generation. All remain-
are now the cheapest sources of new power generation ing countries have full data as far as 2019. G20 countries, which
in Africa. Countries such as Morocco and Kenya have comprise 84% of world electricity generation, each have a sep-
made impressive progress. Other countries, including arate in-depth country analysis. All the data can be viewed and
South Africa, will add significant new investments in these downloaded freely from Ember’s website.
technologies in 2021 and beyond. As the share of these
Electricity + Control JUNE 2021 11ENERGY MANAGEMENT + THE INDUSTRIAL ENVIRONMENT
Smart energy management can
minimise downtime
Martin van Zyl, Segment Leader, Consumer Packaged Goods at Schneider
Electric highlights critical considerations in energy management and equipment
maintenance to achieve stable production and consistent product quality.
B
y design, critical industrial equipment provides Power quality Martin van Zyl,
Schneider Electric.
exceptional longevity coupled with robust quality, Power quality issues can go unno-
features that allow manufacturing facilities to run ticed and have a major impact on operations and process-
optimally and, more importantly, continuously. Often, es, leading to equipment damage, degradation of equip-
however, little thought is given to the realistic lifespan of ment longevity and unplanned downtime. And these issues
such critical equipment and this can result in failures with are more common than one would expect. It’s estimated
sometimes catastrophic consequences. that 70% of power quality disturbances originate within fa-
Complacency leads to the failure to maintain and upgrade cilities and cause between 30 and 40 % of resulting down-
equipment. With critical equipment such as generators and time incidents.
uninterrupted power supplies (UPSs) included in this mix – Here, a power management system has the analytical
and operating without efficient monitoring – a manufacturing tools to help manufacturers understand which power quality
plant is set for the risk of failure. events could adversely affect operations. Manufacturers
The reliability of equipment and continuous power can monitor and analyse power quality disturbances to
supply form a fundamental part of business sustainability, determine specific actions needed to correct issues. This
particularly when it comes to production continuity and might include the installation of power quality correction
avoiding downtime. This is especially true for industries equipment, such as Power Factor Correction and Active
such as food and beverages and pharmaceuticals where Harmonic Filters.
the quality of manufactured products is non-negotiable.
Accelerating the benefits
Monitor, monitor, monitor Monitoring and management are great steps forward – and
The importance of monitoring cannot be overemphasised. more insight can be gained through analysing the collected
At Schneider Electric we understand the value of holistically data in the cloud.
and deeply monitoring critical equipment, using industry The benefit of Schneider Electric’s cloud analytics is
software solutions supported by cloud analytics and expert that the data is evaluated firstly through machine learning
engineers. tools together with research and development information
Translating this into real-life applications and benefits, – and further by an experienced Schneider Electric
it’s important to address the following factors. engineer who will evaluate the results and provide specific
Identify and mitigate power quality issues from both recommendations to the onsite team on how to proactively
internal and external sources through continuous prevent an issue from becoming a safety or downtime
monitoring. event.
Improve power quality to reduce equipment failure, A typical basic example of cloud analytics services
prolong equipment lifespan and eliminate unknown might be in the monitoring of a transformer’s busbar
tripping-and-stoppage events. temperatures in context of the ambient operating conditions
Reduce energy costs by pinpointing savings oppor- and load profile, to understand when these contextualised
tunities related to operational usage, power quality thresholds are exceeded – which would then require
mitigation measures and utility optimisation initiatives. immediate intervention on site, such as tightening of cable
Leverage contextual information such as busbar tem- or busbar connections. Cloud applications will therefore
perature, ambient conditions, the number of opera- evaluate a holistic data set and its relation to critical assets,
tions, the loading of the equipment and information such as a transformers or UPSs, to identify potential issues
from other condition sensors for insightful monitoring long before a failure occurs.
of smart, critical, electrical equipment. Now is the time to focus on equipment reliability, using
Safety First through connected MV (medium voltage) intelligent monitoring and management tools coupled
and LV (low voltage) switchgear that provides remote to cloud analytics that can predict unplanned downtime
switching functionality to establish safe environments, events and prevent possible failure. □
keeping employees out of harm’s way while also em-
powering quick response time through remote moni-
For more information visit: www.se.com
toring and control.
12 Electricity + Control JUNE 2021ENERGY MANAGEMENT + THE INDUSTRIAL ENVIRONMENT : PRODUCTS + SERVICES
A new decade of renewables
More than 260 GW of renewable energy capacity was
added to global energy supply in 2020, beating earlier
estimates and all previous records, despite the economic
slowdown that resulted from the Covid-19 pandemic.
The International Renewable Energy Agency’s
(IRENA’s) annual Renewable Capacity Statistics 2021,
released 5 April, shows that renewable energy’s share
of all new generating capacity rose substantially for the
second year in a row. More than 80% of all new electricity
capacity added last year was renewable, with solar and
wind accounting for 91% of new renewables.
Renewables’ rising share of the total is partly
attributable to net decommissioning of fossil-fuel power
generation in Europe, North America and for the first time
across Eurasia (Armenia, Azerbaijan, Georgia, Russian Solar and wind energy accounted for 91% of the record
260 GW of new renewables power generation installed in 2020.
Federation and Turkey). Total fossil-fuel additions fell to
60 GW in 2020 from 64 GW the previous year, highlighting than in 2019, and Oceania remained the fastest growing
a continued downward trend of fossil-fuel expansion. region (+18.4%), although its share of global capacity
IRENA Director-General Francesco La Camera said, is small and almost all expansion occurred in Australia.
“These numbers tell a remarkable story of resilience
and hope. Despite the challenges and the uncertainty Highlights by technology
of 2020, renewable energy emerged as a source of Hydropower: Growth in hydro recovered in 2020,
undeniable optimism for a better, more equitable, with the commissioning of several large projects
resilient, clean and just future. The great reset offered a delayed in 2019. China added 12 GW of capacity,
moment of reflection and a chance to align our trajectory followed by Turkey with 2.5 GW.
with the path to inclusive prosperity, and there are signs Wind energy: Wind expansion almost doubled
we are grasping it. in 2020 compared to 2019 (111 GW compared
“Despite the difficult period, as we predicted, 2020 to 58 GW). China added 72 GW of new capacity,
marks the start of the decade of renewables,” La Camera followed by the United States (14 GW). Ten other
continued. “Costs are falling, clean tech markets are countries increased wind capacity by more than
growing and never before have the benefits of the energy 1 GW in 2020. Offshore wind increased to reach
transition been so clear. This trend is unstoppable, but around 5% of total wind capacity in 2020.
as the review of our World Energy Transition Outlook Solar energy: Total solar capacity has now
highlights, there is a huge amount to be done. Our reached about the same level as wind capacity,
1.5 degrees outlook shows significant planned energy largely a result of expansion in Asia (78 GW) in
investments must be redirected to support the transition 2020, with major capacity increases in China
if we are to achieve 2050 goals. In this critical decade of (49 GW) and Vietnam (11 GW). Japan added
action, the international community can look to this trend over 5 GW, India and Republic of Korea both
as a source of inspiration to go further,” he said. expanded solar capacity by more than 4 GW. The
The 10.3% rise in installed capacity represents expan- United States added 15 GW.
sion that beats long-term trends of more modest growth Bioenergy: Net capacity expansion fell by half
year on year. At the end of 2020, global renewable gen- in 2020 (2.5 GW compared to 6.4 GW in 2019).
eration capacity amounted to 2 799 GW with hydropower Bioenergy capacity in China expanded by over
still accounting for the largest share (1 211 GW), although 2 GW, and in Europe, the only other region with
solar and wind are catching up fast. The two variable significant expansion in 2020, by 1.2 GW, a
sources of renewables dominated capacity expansion in similar to 2019.
2020 with 127 GW and 111 GW of new installations for Geothermal energy: Very little capacity was
solar and wind respectively. added in 2020, mainly in Turkey, 99 MW, and
China and the United States were the two outstanding smaller expansions in New Zealand, the United
growth markets from 2020. China, already the world’s States and Italy.
largest market for renewables, added 136 GW last year, Off-grid electricity: Off-grid capacity grew by
the bulk coming from 72 GW of wind and 49 GW of 365 MW in 2020 (2%) to reach 10.6 GW. Solar
solar. The United States installed 29 GW of renewables expanded by 250 MW to reach 4.3 GW and hydro
last year, nearly 80% more than in 2019, including 15 GW by about 1.8 GW.
of solar and around 14 GW of wind. Africa continued to
expand steadily with an increase of 2.6 GW, slightly more For more information visit: www.irena.org
Electricity + Control JUNE 2021 13ENERGY MANAGEMENT + THE INDUSTRIAL ENVIRONMENT : PRODUCTS + SERVICES
Windaba 2021 scheduled for October
The South African Wind Energy Association (SAWEA) has
opened its registration platform for WINDABA 2021, which
will be held under the theme: ‘Renaissance of the Wind
Energy Industry - Delivering Economic Benefits for SA’.
The two-day event, planned to return to the Cape Town
International Convention Centre (CTICC) after the 2020
hiatus, is scheduled to take place over 7 and 8 October
2021. Now in its 10th consecutive year, the event is once
again supported by the Global Wind Energy Council
(GWEC).
Speaking to the theme, SAWEA CEO, Ntombifuthi Ntuli
says, “We are celebrating the rebirth of the wind industry Windaba 2021 will celebrate the rebirth of the wind energy
this year, hence the theme is aligned with the positive industry and the benefits it brings to the SA economy.
development in the sector. Last year we saw the Ministerial attracting over R80.5 billion investment into the economy.
determination for procurement of renewables and other Over 100 wind turbine technicians have been trained and
energy technologies being issued, promptly followed by have graduated; 30 000 job years have been created; and
the long awaited Bid Window 5 of the REIPPPP, which was beneficiary communities across the country have been
issued this March, after a seven-year interim period. So it is empowered.
indeed a new season for the sector and the opportunity to “Today we have a solid and mature industry ready to
deliver on the much anticipated economic benefits for the build an additional 14.4 GW of wind power capacity over
South African economy.” the next decade – which will constitute a fair share of the
The wind industry has come a long way since the country’s total power system and is a vision that will be
launch of South African government’s REIPPP programme unpacked at WINDABA this year,” Ntuli added.
and the first bidding window in 2012. During this decade, The 2021 United Nations Climate Change Conference,
almost 3.4 GW capacity of wind power has been built, COP26, is also scheduled for later this year, and will bring
Teaming up to simulate next generation energy systems
The Generation Division of Siemens Energy AG has adopted efficiently to our customers. We thank Siemens Energy for
Simcenter™ software from Siemens Digital Industries selecting Simcenter, part of the Xcelerator portfolio, as their
Software as the core simulation technology for developing simulation platform as they develop the next generation of
its next generation energy systems. Siemens Energy’s sustainable, reliable and affordable energy systems.”
Generation Division has long partnered with Siemens The collaboration is fostering concurrent multidisciplinary
Digital Industries Software for design and simulation and optimisation that encompasses feature-based geometry,
now, through expanded use of the Simcenter portfolio, the reacting flow, conjugate heat transfer, and automated
company has adopted a new approach to simulation that dataflow between analyses. This has resulted in increased
is reducing time to market and improving reliability. product efficiency, longer life and lower emissions. The
Jean-Claude Ercolanelli, Senior Vice President of shift has enabled the Generation Division of Siemens
Simulation and Test Solutions, Siemens Digital Industries Energy to manage the transition from historical methods
Software, said: “We share more than the name Siemens and tools to new methods and applications, providing an
– we are both committed to pushing the boundaries of integrated data flow across the design chain by breaking
technology to deliver the most reliable solutions more down discipline silos. It has also enabled a deeper, more
External and internal temperature and flow
paths for a typical turbine blade, simulated with
Simcenter STAR-CCM+ software.
14 Electricity + Control JUNE 2021ENERGY MANAGEMENT + THE INDUSTRIAL ENVIRONMENT : PRODUCTS + SERVICES
together world leaders with the spotlight on Net Zero to 3 kW ac-dc power supplies provide
2050 economies. This is a burning issue for South Africa 150 to 800 Vdc
too and will form part of the WINDABA programme.
“We cannot separate wind energy from the climate The HDL3000-HV series
change narrative as the decommissioning of coal power of single-phase input
and deployment of wind and other renewable sources of 3 kW ac-dc power sup-
energy will result in accelerated decarbonisation of the plies with output voltages
power sector, which benefits both the environment and the from 150 V to 400 Vdc,
economy at large,” Ntuli said. and up to 800 Vdc real-
While this year’s conference returns to a physical event, ised by connecting units
following the 2020 online platform amidst the Covid-19 in series, is available
pandemic, it will include certain hybrid elements in from Vepac Electronics.
anticipation of interrupted international travel. All models feature output
“We anticipate that international travel might still be voltage and current adjustment ranging from 0 to 105% The HDL3000-HV
somewhat limited, so we have built a hybrid element using analogue (via voltage or resistance) or digital (I2C, series of 3 kW
into WINDABA 2021, which will ensure our international RS485 and RS232) interfaces, enabling the user to opti- ac-dc power
supplies suits
partners and industry experts can still attend,” Ntuli said. mise and tailor the power solution to the application. applications that
Windaba is the flagship industry conference of SAWEA, The HDL3000-HV series, with constant voltage and need higher supply
bringing together key stakeholders including professionals, constant current operation, addresses applications that voltages.
policymakers, academics, government representatives and require higher supply voltages including: battery test and
civil society. It aims to facilitate strengthened partnerships simulation systems, test and burn-in equipment, laser
for on-the-ground implementation of renewable energy pro- systems, LED curing, lighting and heating, electrolysis,
jects, to influence energy policy, and provide a framework motor drives and cathodic protection.
to aid strategic decision-making. Five output voltage versions are available: 150 V,
200 V, 250 V, 300 V and 400 V, each with a 5 V/0.5 A
For more information or 9 V/0.3 A user-selectable standby output. The output
visit: https://windaba.co.za/portal/registration/ can be trimmed within ±5% in addition to the output
programming function. For applications requiring higher
current, up to eight models can be connected in parallel
engaged relationship between software developers and with active current sharing and built-in O-Ring diodes
designers. simplifying interconnections.
To bring concurrent engineering vision into focus, wide- The fully isolated I2C, RS485 and RS232 interfaces
ranging tools have been used. These include: Simcenter™ provide remote control and monitoring and the LED
3D software for parametric feature-based geometric indicator provides a visual indication of dc OK, output
models and nonlinear structural analysis including not enabled, overvoltage, overload, over temperature,
consideration of material creep; HEEDS™ software for fan failure and AUX standby status. A GUI and full user
automated simulation workflows; Simcenter™ STAR- manual are available to support system development.
CCM+™ software for combustion and thermal analysis; The operating voltage of the HDL3000-HV series
and the extendable NX™ software environment with ranges from 90 V to 264 Vac. When operating at voltages
connectors for integrated design tools. below 180 Vac (low line), the maximum power output
Paul Garbett, Director of Engineering, Large Gas Turbine is 2 000 W. At voltages between 180 Vac and 264 Vac
Modules, Siemens Energy Generation Division, said: (high line), the maximum power output is 3 000 W. When
“Through increased use of robust design methodologies operating at 230 Vac at full load, the unit’s efficiency is
for innovative trusted product designs, improved simulation up to 92%.
workflows for product R&D effectiveness and use of Measuring 170 mm x 64 mm x 301.49 mm, the com-
advanced physics-based simulation for early critical design pact units are cooled by forced airflow from the integrat-
decisions, Simcenter is enabling the Generation Division ed, variable speed fan. Operating temperatures range
to deliver more reliable products to our customers, more between -20°C and +60°C with full power up to +50°C,
quickly.” derating linearly to 50% load at +60°C.
Siemens Digital Industries Software is driving The HDL3000-HV series is safety certified to IEC/
transformation to enable a digital enterprise where UL/EN 62368-1 for AV/ICT equipment. The units also
engineering, manufacturing and electronics design meet comply with EN 55032 Class A conducted and radiated
tomorrow. The Xcelerator portfolio helps companies create emissions, and meet the EN 61000-3-2 harmonics
and leverage digital twins that provide new insights, and EN 61000-4-2 immunity standards. All models are
opportunities and levels of automation to drive innovation. supplied with a three-year warranty from XP Power.
For more information visit: www.sw.siemens.com For more information contact Vepac Electronics.
or www.siemens-energy.com Tel: +27 (0)11 454 8053, email: sales@vepac.co.za
Electricity + Control JUNE 2021 15You can also read
